Work Instruction for Forklift Inspection and Testing

Traceability Table
Modified By Date Revision What Changed
Initial Version 27/8/2019 0 -

Mohammed Hunity 12/8/2020 1 Added all missing acceptance criteria

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 Work Instruction for Forklift Inspection and Testing

1- Standard
BS EN ISO 3691-1:2015
ISO 5057

2- Scope
These instructions are applicable to the following types of forklift trucks:
a) Industrial counterbalanced trucks;
b) Reach trucks with retractable mast or retractable fork arm carriage;
c) Straddle trucks;
d) Pallet-stacking trucks;
e) High-lift platform;
f) Trucks with elevating operator position up to 1 200 mm;
g) Side-loading trucks (one side only);
h) Lateral-stacking trucks (both sides), and lateral and front-stacking trucks;
i) Pallet trucks;
j) Bidirectional and multidirectional trucks;
k) Tractors with drawbar pull up to and including 20 000 N
l) Rough-Terrain counterbalanced trucks;
m) Industrial-trucks powered by battery, diesel, gasoline or LPG (liquid petroleum gas)

3-Work Instruction
3.1 Process
3.1.1 Marking:
 Name and address of the manufacture
 Serial number and manufacture year and compliance with the requirements of this part of ISO3691
 Actual capacity & high lift
3.1.1 The truck shall be provided with a device (e.g. key, code, magnetic card) which prevents starting
without its use.
3.1.2 The Inspector shall equip himself with appropriate safety apparel, safety equipment, instruments and
tools necessary to undertake the procedures detailed hereafter.
3.1.3 There shall be no sharp edges or angles posing a hazard in the area of the operator in the normal
operating position or in the area of access and egress during normal and daily checks.
3.1.4 A parking brake for all industrial trucks shall be designed with service and brakes that shall comply
with ISO 6292, they will be equipped with a system preventing unintentional release.
3.1.5 The inspector shall verify that the type forklift crane is of good construction sound material, of
adequate strength and free from patent defect.
3.1.6 With due reference to the relevant standard check list the inspector shall conduct inspection and tests
that are deemed necessary and timely as to the condition and age of the forklift crane being examined.

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 Work Instruction for Forklift Inspection and Testing

3.1.7 When considered necessary by the inspector, visual examination can be supplemented by methods of
non-destructive testing that determine the condition of any part of the forklift.
3.1.8 The Forklift crane should be properly maintained, be in good working order and be free from dirt,
grease prior to the commencement of the inspection and testing.
3.1.9 All inspections and tests shall be carried out with the crane in a safe working area, in accordance with
the safe working procedures in force at a specific location where the inspection takes place.
3.1.10 However, the same diligent inspection procedures with special regard to the safe function of all
equipment contained on the crane, whether included in the check list or not.
3.1.11 It is important to ascertain the duty classification and rate of wear, as when certifying the forklift “fit
for further service” the amount of wear being considered, is the starting point for that next period of
service.
3.1.12 Travel control on internal combustion engine power trucks shall be fitted with a device which
prevents the engine being stated while the transmission is engaged.
3.1.13 the inspector will define safety factor of the lifting mechanism by using this equation.
𝐾1 = (𝐿𝑐 𝑥 𝑛)/(𝑅 + 𝑤)
K1 safety factor of lifting
Lc minimum breaking load for new chains
N number of chains
R maximum load capacity
W dead weight of lifting mechanism

3.2.1 Piping (Hoses)

3.2.1.1 Pipe must be installed in a way that can’t be damage by head of radiator or leaks
3.2.1.2 Pressure hose above 1 𝑏𝑎𝑟 3 shall be supported at least every 500mm, and must be suitable for
working above 25-75 bar
3.2.1.3 Pressure less than 1 bar must be testing under pressure to maximum working load
3.2.1.4 Aluminum piping shall not be used, and the hose must be short as practical
3.2.1.5 Pressure hoses above 1 bar shall be supported at least every 500 mm, rigid pipes shall be supported
at least every 600 mm
3.3 Fork arms.
3.3.1 Solid section fork arms shall be manufactured and tested in accordance with ISO 2330, expect with
respect to safety factors. The capacity factors are subject to regional requirements, additional to the
requirements of this part of ISO 3691.
3.3.2 The total capacity of all fork arms fitted to a truck shall not be less than the actual capacity of the
truck.
3.3.3 Blade angle exceed 93 degrees, the fork must be replaced
3.3.4 Forks wear 10% reduces load capacity by 20%, at which point the forks must be replaced this can be
measured by fork caliper.
3.3.5 Forks Parallels must be considered in the inspection
3.3.6 Fork identification according to ISO 2330 should be easily legible. In case of missing or unclear
marking the fork should be removed from service.

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 Work Instruction for Forklift Inspection and Testing
3.3.7 Rated capacity load center as the table below:

3.3.8 The difference of tip heights cannot exceed 3% of the blade length.
3.3.9 The material wear on the heel area of the forks cannot exceed 10% of the original section of the fork.
Capacity of the fork is drastically reduce due to material wear.

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3.4 Chain
3.4.1 Chain shall be cleaned for inspection to reveal any damage or crack & wear.
3.4.2 Contact point on the chain must be checked for any wear or losing pin .
3.4.3 Lack of lubrication can cause the pins to twist out of place resulting in chain failure.
3.4.4 Elongation on the chain must measure by using chain gauge roller and the percentage must not exceed
3 percent because a three percent elongation translates to a 15 percent reduction in chain strength
3.5 Mast & Carriage
3.5.1 Mast must be clear from ant bend, crack, twist on it section.
3.5.2 Carriage must be clean and forks pin holder must be locked and easily moved.
3.6 operator’s seat Dimensions
The or standing position shall be so located that the operator has sufficient room while operating the truck so
as to remain within the plan view outline of the truck. The dimensions shall be of suitable and ergonomic
shape to accommodate at least a 5th percentile to a 95th percentile of the population, the seat shall not extend
beyond the plan view of the truck.
Minimum distance from top edge of seat beck to the plan view outline shall be 50 mm
For tiller steering control movement may extend beyond the plan view.
3.7 Operator access and egress
Trucks shall be designed to permit safe and easy access and egress and to minimize the risk of slipping,
falling and tripping.
Steps, running boards and hand holds (grab handles, fixed parts of the truck structure,) shall be provided
above a step height of 350 mm to give three-point contact at all height
Step width, instep clearance shall comply with ISO 2867
3.8 Steps shall have resistance surfaces or covering, the first step shall be not more than 550 mm from
ground and succeeding steps shall be 250 mm to 350 mm, preferably at equal intervals.
3.9 Compartment floors
The compartment floor frequented by the operator, steps and walkways shall be free of obstacles and shall
have a slip resistance surface.
3.10 Walkways
Walkways more than 2000 mm from the ground shall have guard rails. The guard rails shall have a height of
900 mm to 1100 mm and shall be capable of withstanding, without permanent deformation, a force of 900 N
applied in a horizontal direction from the inside to the outside
3.11 Hand holds
For access to and egress from the normal operating position with a floor height above 300 mm, hand holds
shall be provided; these may be part of the truck structure. The clearance dimension for a hand hold shall be
at least of 45 mm width, 130 mm length and diameter of 15 mm.
3.12 Load Test:
3.12.1 The Load weight must be identified before it used by knowing the accurate weight of it and his
dimension.
3.12.2 Making the load test on weight that equivalent to the rated capacity of the forklift.
3.12.3 The result of functional load tests that are undertaken as part of routine inspection procedures shall be
identified on the certificate & report (satisfactory or otherwise).

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 Work Instruction for Forklift Inspection and Testing
3.13 Documentation
- Electric traveling forklift inspection check list
3.13.1 The inspector shall report the result of his examination with details, if any, of repairs, renewals or
alterations required enabling the crane to continue to be used with safety.
3.13.2 A certificate of inspection and Test shall be issued, should the crane be deemed fit for further service.
3.13.3 The re-inspection period shall not exceed twelve months from the date of inspection.
3.13.4 Fork inspection by check of any cracks, straightness, and fork angle, tip alignment, bled wean.
3.13.5 Check chain wear gage that have ability to work under load. And check for any worn or straight edge.
4. Load test
4.1 Check the rated capacity from the manufacture manual book and select the maximum load standard dead
weight.
4.2 check the proper control function and control movement without load.
4.3 lift the dead weight to max high and lift the rated load by fork lift and open full mast.
4.4 Hold the weight for minimum 10.0 min.

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